Lightweight carbon foam structure for phase change material heat sinks

Abstract

A phase change material heat sink including: a carbon graphite matrix having one or more removed portions; and an expanded graphite located within the one or more removed portions.

What is claimed is: 
     
       1. A method of manufacturing a phase change material (PCM) heat sink, the method comprising:
 obtaining a carbon graphite matrix; 
 after obtaining the carbon graphite matrix, machining the graphite matrix to remove one or more portions therefrom to form one or more removed portions such that the carbon graphite matrix is a modified carbon graphite matrix having a porosity between 50% and 95%; and 
 inserting an expanded graphite into the one or more removed portion of the modified carbon graphite matrix, 
 wherein the expanded graphite fills a selected percentage of the one or more removed portions; and 
 wherein the selected percentage is less than or equal to 10 percent; and 
 inserting a PCM into the one or more removed portions. 
 
     
     
       2. The method of  claim 1 ,
 wherein machining includes machining one or more holes in the carbon graphite matrix to form the one or more removed portions. 
 
     
     
       3. The method of  claim 1 ,
 wherein machining includes machining one or more channels in the carbon graphite matrix to form the one or more removed portions. 
 
     
     
       4. The method of  claim 1 , further comprising:
 inserting the modified carbon graphite matrix and the expanded graphite into a sealed chamber. 
 
     
     
       5. The method of  claim 4 , further comprising:
 inserting a phase change material into the modified carbon graphite matrix and the expanded graphite located within the sealed chamber. 
 
     
     
       6. The method of  claim 4 , further comprising:
 inserting a phase change material into the modified carbon graphite matrix simultaneously with the expanded graphite. 
 
     
     
       7. The method of  claim 4 , further comprising:
 inserting a phase change material into the modified carbon graphite matrix simultaneously with the expanded graphite via a vacuum. 
 
     
     
       8. The method of  claim 4 , further comprising:
 inserting a phase change material into the modified carbon graphite matrix and the expanded graphite via a vacuum.